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  #181  
Old 07-18-2018, 10:30 PM
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jcarne jcarne is offline
 
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Fuselage work continues, I started the day with doing the conical bend. Not gonna lie, this had me stressed a little as I have seen countless threads of people getting cracks while doing this. There is a simple fix for the cracks but I would rather just avoid them altogether.

I did the bend in two passes, no more as you will eventually start to work harden the metal. The first pass was with a 4x4 as the edges have a nice fillet to them.

20180718_112338 by Jereme Carne, on Flickr

After there was some bend I switched to an angle as you have to bend past 90 degrees.

20180718_112519 by Jereme Carne, on Flickr

Here is how the left side turned out.

20180718_114840 by Jereme Carne, on Flickr

20180718_114845 by Jereme Carne, on Flickr

And the right side...

20180718_114902 by Jereme Carne, on Flickr

Overall I think they came out quite nice. I about crapped a brick when I saw those hole line up nicely especially after pondering the fact that the whole process took less than 15 minutes per side. They may need a little tweak eventually depending on how the baggage bulkhead fits.

Also worth mentioning that I thoroughly deburred the reliefs before bending.
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  #182  
Old 07-18-2018, 11:36 PM
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After the conical bends it was on to the arm rests.

20180718_154829 by Jereme Carne, on Flickr

Then most of my day was spent drilling the longerons. This step is taking way longer than I thought but oh well, it's nice to be drilling things again.

20180718_211051 by Jereme Carne, on Flickr
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  #183  
Old 07-19-2018, 01:29 PM
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Those belly bends look pretty sweet Carne.

Quit priming everything and you will be done way sooner!

Alclad!
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  #184  
Old 07-19-2018, 08:07 PM
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Default Doublers for armrests

May I suggest while you are there, adding doublers to your armrests. Some .032 angle (sheet Bent) riveted to the inner edge and tying into to the bulkhead and vertical spar box makes a big difference in how sturdy the armrest feels and lowers the risk of bending when in use.
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  #185  
Old 07-20-2018, 12:01 AM
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jcarne jcarne is offline
 
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Quote:
Originally Posted by kentlik View Post
Those belly bends look pretty sweet Carne.

Quit priming everything and you will be done way sooner!

Alclad!
I think about this almost every day, unfortunately my conscious just won't avoid the green stuff.

Quote:
Originally Posted by rjcthree View Post
May I suggest while you are there, adding doublers to your armrests. Some .032 angle (sheet Bent) riveted to the inner edge and tying into to the bulkhead and vertical spar box makes a big difference in how sturdy the armrest feels and lowers the risk of bending when in use.
Thanks for the reminder good sir, I have seen it done on a few peoples blogs and was planning on doing it myself. I was going to go with some 0.063 angle riveted in there.
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  #186  
Old 07-20-2018, 12:11 AM
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Well I wrestled with the firewall today. I'm not sure if I was supposed to flute the stainless or not but I did since the middle was bowing out a little. (after doing some research it looks like you are not supposed to flute here as the piano hinge for cowl resides there, so if you are reading this don't flute here! If however you have like myself, we are not alone, get the squeezer out with some flat sets and flatten em out. Live and learn) I have also read on many many blogs that the forward fuse section is a freakin land mine of potential edge distance problems. Therefore, I am going to mark everything with black for minimum edge distance and blue is what I always use for what I'm actually shooting for. This already paid off today as the top left firewall bracket was very very close to this minimum.

20180719_144713 by Jereme Carne, on Flickr

Finally got the firewall drilled to the side skins.

20180719_185314 by Jereme Carne, on Flickr

I also started the cut outs for the gear leg mounts. It got to about 10:15pm and I thought I better stop making noise. We will finish these tomorrow.

20180719_213213 by Jereme Carne, on Flickr
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Last edited by jcarne : 07-20-2018 at 12:21 AM.
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  #187  
Old 07-21-2018, 09:54 AM
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After finishing the gear leg mount holes it was time to install the various angles for the forward fuselage.

After the F-713 auxilary longerons were installed it was on to the F-719 stiffeners. The F-719 angles took quite some time as the clips can have an edge distance problem if your not careful making them.

20180720_163916 by Jereme Carne, on Flickr

Then it was on to the lower longerons, these guys have gotten many a great builders in trouble with edge distance. You can see why in this next pic. Van's tells you to drill your holes 1/2" in from the edge of the angle, I haven't read a single blog where 1/2" didn't get someone in trouble with edge distance on the steel. Therefore, mark the edge of the angle on the steel, remove the angle and measure beteween the edge distance black line and the line you just drew. For me it was barely over 3/8". I drilled the holes in the lower longeron angles about 3/8" - 7/16" in from the edge. You can see in this next pic how exact you have to be... Very close to minimum edge distance on both parts.

20180720_174930 by Jereme Carne, on Flickr

Then I drilled to 5/32 and finally reamed to 3/16.

Thing of beauty right here.

20180720_175702 by Jereme Carne, on Flickr
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  #188  
Old 07-21-2018, 11:05 AM
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Exceptional work my brother! I have been sitting on my butt staring at the canopy frame for a month...it's still there...
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  #189  
Old 07-24-2018, 01:08 AM
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Quote:
Originally Posted by kentlik View Post
Exceptional work my brother! I have been sitting on my butt staring at the canopy frame for a month...it's still there...
Time to get busy Kent! I don't want to be the only one flying in a year or so.
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RV-7A Emp. done
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Finish kit arrived
Exempt but gladly paying!
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  #190  
Old 07-24-2018, 01:24 AM
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jcarne jcarne is offline
 
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Man I tell you what, this forward fuselage was a tricky one. I made it through the whole thing without having to order replacement parts (so far).
There are quite a few spots that could get you in trouble with edge distance problems, just take your time and measure accurately.

Edge distance came out nice on these guys but it was time consuming to make sure I got it.

20180721_125505 by Jereme Carne, on Flickr

The forward bulkhead is another spot edge distance could get you in trouble if your not paying close attention.

20180721_192310 by Jereme Carne, on Flickr

This guy took quite some time to get fitting right. I also still need to upsize some holes.

20180721_192316 by Jereme Carne, on Flickr

Kinda fun installing the rudder pedals. I drilled three positions for these guys, although I know I'm probably going to need to the most aft one since I'm flippin short!

20180723_140305 by Jereme Carne, on Flickr

If you don't own a right angle attachment or drill it's time to get one if your approaching this part of the build, I had to use it in quite a few spots.

20180723_181241 by Jereme Carne, on Flickr

My right angle attachment couldn't get on the the aft most hole in these cover brackets so I got creative. Not in the picture was me with my other hand holding a cleco against the middle part of the drill bit to keep it straight instead of bowed.

20180723_184006 by Jereme Carne, on Flickr
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Finish kit arrived
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